Semi-conducting layer for insulated electrical conductors

ABSTRACT

A semi-conducting pyrolyzed glass fiber layer equalizes the electrical potential on the exterior surface of an insulated conductor when the layer covers the surface. The layer prohibits the development of a corona discharge and bleeds off any electrical charge developed thereon when the layer is electrically coupled to a body having a known potential. The insulated conductor may be windings in a dynamoelectric machine.

This is a division of application Ser. No. 07/351,235, filed May 15,1989 which is, in turn, a divisional of application Ser. No. 643,908,now U.S. Pat. No. 4,853,565, filed Aug. 23, 1984.

BACKGROUND OF THE INVENTION

This invention relates to a semi-conducting pyrolyzed glass fiber layercovering an insulated electrical conductor which prohibits thedevelopment of a corona discharge when an electrical potential existsbetween the conductor and region adjacent the exterior surface of theinsulator.

In many electrical devices, an electrical potential exists between aconductor and the regions immediately adjacent the exterior surface ofan insulator surrounding the conductor. In a high powered electricalapparatus such as a dynamoelectric machine, the stationary armature coreis generally made of laminations which define a cylindrical bore andwhich also define circumferentially spaced radial slots opening into thebore and axially extending substantially the length of the stator core.Heavily insulated electrical windings, or armature bars, are disposed inthe slots. A high electrical potential difference exists between thewindings or armature bars and the members of this stator defining theslots which are at an electrical ground.

The aforementioned large electrical potential difference may besufficient to produce ionization of the gaseous medium in the regionadjacent the exterior surface of the insulation surrounding the armaturebars. This ionization tends to initiate arcing along the surface of theinsulated armature bars which bridges the insulated path from thewindings to the grounded stator laminations.

A similar problem has been recognized in the end turn region of thedynamoelectric machines. In that region, the insulated armature barsextend beyond the respective slots and one set of bars iscircumferentially bent from top to bottom, to circumferentiallydisplaced slot positions so as to provide a connection between one barand another circumferentially spaced bar in the stator.

The ionization of the gas immediately adjacent the insulation of thearmature bars is recognized as the production of a corona discharge. Inthe past, corona has been avoided by wrapping the insulated armaturebars with a grounding tape which bleeds off the electric chargedeveloped on the exterior surface of the insulator. The grounding tapeis in electrical contact with the stator laminations. The grounding tapelongitudinally extends the axial length of the bar in the stator slot aswell as extends into a portion of the end turn region beyond the slot.

It is common to place the taped insulated armature bars in a resin bathand vacuum pressure impregnate the resin into the entire structure. Thisprocedure may result in a change of the value of resistivity per squareof the grounding tape, therefore, the ability of the tape to preventcorona is not entirely preserved. The change in resistivity of thegrounding tape, when acted upon by resin, is well known in the art.Also, the grounding tape may abrade due to the vibration of the armaturebar in the stator slot.

The development of a corona discharge in the region adjacent aninsulated winding is not limited to dynamoelectric machines since thisphenomenon has been noted in other electromagnetic machines such aslarge AC motors. In those machines, the insulated windings are disposedin longitudinally extending slots in the stator. Commonly, groundingtape is placed on the exterior surface of the insulation and iselectrically in contact with the members of the stator defining the slotto minimize the possibility of a corona discharge similar in nature tothat which occurs in dynamoelectric machines.

The development of a corona discharge and the resulting possibility of aflash over between the windings and the electrical ground adjacent tothe exterior surface of the insulator is one extreme of the generalproblem of electrical charge buildup on the exterior of an insulatedwinding. This buildup of electrical charge is sometimes caused by thecapacitive characteristics of the device. For example, cables carryinghigh voltages are sometimes subject to charge build-up on the exteriorsurface of the cable's insulation. Also, insulated conductors intransformers are affected by this capacitive charge build-up. The chargemay also be a static electric charge. The grounding tapes utilized inprior art devices are not well suited to bleed off this electric chargeunless the electrical apparatus is shaped such that the tape is in closecontact with the entire insulated surface. For complex shapes, thoseshapes other than round or rectangular shapes with rounded corners, thegrounding tape is not easily placed in close contact. In thosesituations, the portions of the exterior surface which are not inintimate contact may have an electrical charge buildup thereon since thetape does not bleed off the charge to ground.

Static charge build-up problems have been recognized as affectingsensitive electronic equipment, such as integrated circuit chipsutilized in digital electronic equipment. The manufacture of these ICchips is generally sensitive to static charges on the conveyors,handling trays, racks and other means of packaging, handling, mountingand transporting. In the past, conductive paints were utilized to renderthe part, such as a plastic handling tray, semi-conducting. The tray waselectrically grounded by an appropriate means to bleed off the staticelectric charge.

OBJECTS OF THIS INVENTION

It is an object of this invention to provide for a layer in intimatecontact with the insulated windings of an electrical machine and inelectrical contact with ground to bleed off charges thereon and tominimize the possibilities of a corona discharge.

It is an additional object of this invention to provide asemi-conducting layer which substantially maintains its value ofresistivity after resin impregnation of the assembled insulatedelectrical winding.

It is a further object of this invention to provide for asemi-conducting pyrolyzed glass fiber material which can be laid overcomplex shapes to minimize voids and gaps between the layer and theinsulation.

It is an additional object of this invention to provide means formaintaining a substantially uniform and equal electrical potential overthe exterior surface of a substrate.

SUMMARY OF THE INVENTION

In one embodiment of the invention, a semi-conducting pyrolyzed glassfiber layer, having a resistivity in the range of 200 to 10,000,000 ohmsper square, is disposed in intimate contact with the outer surface ofthe insulation of an insulated winding. The insulated winding isdisposed in a slot along the axial length of an electrical machine. Whenan electric potential exists between the windings and the members of theelectrical machine defining the slot, and the semi-conducting layer isin electrical contact with the slot members, the electric chargedeveloped on the outer surface of the insulation is bled off to the slotmembers of the machine.

In another embodiment of the invention, a plurality of semi-conductinglayer-like segments, having increasingly greater degrees of resistivitywithin the above-noted range, are sequentially disposed along the outersurface of the insulated windings which extend beyond the end of theslot.

Another embodiment of the invention utilizes a layer of semi-conductingpyrolyzed glass fiber as an internal grading layer disposed between aninner transposition filler material, which is proximate the transposedstrands in an electrical winding, and the insulation surrounding thebundle of strands. The semi-conducting layer is in intimate mechanicaland electrical contact with both strands. Other embodiments of theinvention are detailed hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularlypointed out and distinctly claimed in the concluding portion of thespecification. The invention, however, together with further objects andadvantages thereof, may best be understood by reference to the followingdescription taken in connection with the accompanying drawings in which:

FIG. 1 is a cross sectional view of an insulated winding which has alayer of semi-conducting material substantially covering the outersurface of the insulation;

FIG. 2 is a cross sectional view of a slot of an electrical machinewhich holds two insulated windings;

FIG. 3 is a magnified view of the cut-away area designated in FIG. 2;

FIG. 4 is a longitudinal view of a cut-away portion of the insulatedwinding disposed in the slot as viewed from the perspective of sectionline 4--4' in FIG. 2;

FIG. 5 is a perspective cutaway view of a portion of the end turn regionof a dynamoelectric machine;

FIG. 6 is a cross sectional view of an insulated winding detailing aninternal grading layer;

FIG. 7 is a cross sectional view of a cable; and

FIG. 8 is a cross sectional view of an electrical housing surroundingdigital electronic equipment.

DETAILED DESCRIPTION

FIG. 1 illustrates a cross sectional view of an insulated electricalwinding 10. Winding 10 includes a plurality of conductive elements orstrands 12 positioned in two adjacent columns. Each strand is surroundedby strand insulation 14. A better understanding of the construction ofan electrical winding is disclosed in U.S. Pat. No. 3,158,770,Coggeshall et al., which is incorporated herein by reference thereto.The bundle of strands is surrounded by heavy ground insulation 16. Alayer 18 of semi-conducting pyrolyzed glass fiber is in intimate contactwith and substantially covers the outer or exterior surface ofinsulation 16. Semi-conducting layer 18 has a resistivity in the rangeof 200 to 10,000,000 ohms per square. As used herein, the word"semi-conducting" refers to a material which has a resistivityintermediate that of a good insulator, which is recognized to have aresistivity in the range of 10¹² ohms per square or more, and that of agood conductor, which is considered as having a resistivity of 10⁻¹ ohmsper square or less. The recommended range of resistivity for layer 18 is200 to 100,000 ohms per square. It is to be recognized herein that thedepth of layer 18, as illustrated in all the figures, is exaggerated fordescriptive reasons. Also, it is to be recognized that layer 18 may beclassified by some strict standards as an insulator. However, forpurposes of understanding, layer 18 is shown as a distinct layerthroughout the illustrations.

One method of making the semi-conducting pyrolyzed glass fiber, having aresistivity within the above-noted range, is to heat treat glass fibersin the substantial absence of oxygen and in the presence of an effectiveamount of organic compound to secure the desired semi-conductingcharacteristics. A detailed description of this method, and othercomparable methods, of making the semi-conducting pyrolyzed glass fibersis disclosed in the copending application of Richard K. Elton entitled"Semiconductive Glass Fibers And Method", Ser. No. 548,338, now U.S.Pat. No. 4,510,077, filed on Nov. 3, 1983, and assigned to the sameassignee as the present application and incorporated herein in itsentirety by reference thereto.

Winding 10 may be constructed as is well known in the art by immersingthe winding in a bath of resin and vacuum pressure impregnating theresin in the winding. Other methods of constructing the winding are alsowell known to those of ordinary skill in the art. Such impregnatingprocedure eliminates the voids and gaps between semi-conducting layer 18and the outer or exterior surface of insulation 16. Experiments haveshown that the resistivity of the semi-conducting layer before and afterthe resin impregnation does not substantially change as compared withthe grounding tape in prior art devices.

When an electrical potential exists between the bundle of strands andthe region immediately adjacent the exterior surface of insulation 16,semi-conducting layer 18, when in electrical contact with an electricalground, bleeds off the electric charge on that surface. This bleedingoff of the electric charge prohibits the development of a coronadischarge in the region immediately adjacent the exterior surface ofwinding 10, thereby preventing the erosion of the insulation anddecreasing the possibilities of a flash over through insulation 16 fromthe strands to an electrical ground proximate the exterior surface.

Semi-conducting layer 18 substantially covers the outer surface ofinsulation 16 thereby providing a uniform and equal potential over thatsurface.

FIG. 2 illustrates a cross sectional view of a slot 20 of an electricalmachine. As is well known in the art, large electromagnetic machines,such as dynamoelectric machines and large AC motors, have anelectrically grounded core defining axially extending, circumferentiallyspaced, radially directed slots. The slots are longitudinally extendingboth in the stator and rotor sections. The stator defines a cylindricalbore with the slots opening into the bore and the rotor is cylindricallyshaped with the slots opening to the radially outer surface. A pluralityof insulated electrical windings are disposed axially in these slots. Asillustrated in FIG. 2, two insulated electrical windings, similar towinding 10, are disposed in slot 20. The resistivity range forsemi-conducting layer 18 when covering the winding in the slot isbetween 200 and 100,000 ohms per square. Numerals designate similarelements in FIG. 1 and FIG. 2 and those designations are carried forwardin FIGS. 3 and 4. The two windings are held in place by slot wedge 22cooperating with dovetail groove 24 which is part of the retainingmeans.

In the illustrated example of a dynamoelectric machine, statorlaminations 26 are the members defining slot 20. Laminations 26 are atan electrical ground. Semi-conducting layer 18 substantially covers bothwindings independently, extends along substantially the axial length ofthe machine and is in mechanical and electrical contact with laminations26 therefore, the exterior surface of insulation 16 is at asubstantially uniform and equal electrical potential.

As is well recognized in the art, the armature bars or electricalwindings in a dynamoelectric machine's stator may vibrate due to thelarge electrical potential in the windings. To limit the vibrations, aripple spring 30 is placed between one side of the windings and theadjacent slot wall 28. The spring is part of the retaining means. Adetailed description of the ripple spring system is disclosed in theaforementioned Coggeshall U.S. Pat. No. 3,158,770. Ripple spring 30 maybe a fiber glass reinforced spring with a semi-conducting pyrolyzedglass fiber layer or coating substantially covering the spring similarin nature to that described herein. The semi-conducting layer on theripple spring insures that the development of a corona in thatparticular region of the slot is prohibited due to the layer'smechanical and hence electrical contact with slot wall 28 and thebalance of the grounded core members.

FIG. 3 illustrates a magnification of the designated portion in FIG. 2.Semi-conducting layer 18 is in electrical contact with lamination 26 dueto its mechanical contact with slot wall 28. The intimate contactbetween semi-conducting layer 18 and insulation 16 is produced by resinimpregnation or other methods wherein both layer 18 and insulation 16are bonded together by compatible resinous agents. The copending patentapplication of Elton, Ser. No. 548,338, now U.S. Pat. No. 4,510,077,discloses the attributes of the pyrolyzed glass fiber layer in greaterdetail.

The electrical windings for a large AC motor are substantially similarto that described with respect to the exemplary dynamoelectric machinedescribed herein. Several insulated electrical windings are disposed inslots longitudinally defined by either the stator or the rotor of themotor. The insulated windings are substantially covered by thesemi-conducting layer and placed within the slots. The semi-conductinglayer is in electrical contact with the sides of the slots, and hence, abuildup of electrical charge on the exterior surface of the insulationis prohibited due to the electrical contact between the semi-conductinglayer and the grounded slot members. As is recognized in the art, it isnot always necessary to utilize a ripple spring in an AC motor.

FIG. 4 is a partial cut-away, longitudinal view taken from theperspective of section line 4--4' of FIG. 2. The stator laminations 26of the exemplary dynamoelectric machine are grouped in packages 27 withcooling passages 32 therebetween. Ripple spring 30 contacts winding 10at contact points 31 as designated and the spring contacts thelaminations at contact points 33.

FIG. 5 illustrates a cut away perspective view of a portion of the endturn region at one end of a dynamoelectric machine. Armature bars orinsulated electrical windings 50 extend beyond the stator core definingslots 52. Insulated electrical windings 50 initially extend axially andthen bend circumferentially so as to provide a connection between onebar and a second circumferentially disposed bar in the stator core. Adetailed description of the end turn region is disclosed in U.S. Pat.No. 3,354,331, Broeker et al., which is incorporated herein by referencethereto.

Various insulated blocks 54, ties 56, and axial brackets 58a, 58b and58c provide support for the windings. The windings are insulated byheavy insulation 60. The portion of the insulated electrical windings inRegion A are substantially covered with a semi-conducting pyrolyzedglass fiber layer 62 generally similar to semi-conducting pyrolyzedglass fiber layer 18 described herein. However, the range of resistivityof all semi-conducting layers beyond slot 52 is between 200 and10,000,000 ohms per square. The semi-conducting layer 62 hassubstantially the same value of resistivity as does the semi-conductinglayer throughout the axial expanse of the winding and, in Region A, isgrounded to the stator core laminations by mechanical contact with thoselaminations. Region A extends a predetermined length beyond the end ofslot 52.

Region B extends beyond the predetermined length of Region A. In RegionB, a second plurality of semi-conducting pyrolyzed glass fiberlayer-like segments 65a, 65b, 65c and 65d are utilized and each segmenthas an increasingly greater degree of resistivity than the precedingsegment which in this region may be as high as approximately 10,000,000ohms per square. The method of making the glass fiber with differinglevels of resistivity is disclosed in Richard Elton's copending patentapplication Ser. No. 548,338, now U.S. Pat. No. 4,510,077. Thesesegments are sequentially disposed along the length of the winding inRegion B with increasing degrees of resistivity beginning with segment65a, proximate the Region A. Therefore, the semi-conducting segmentfarthest from Region A, segment 65d, has a relatively higher value ofresistivity than the semi-conducting segment proximate Region A, segment65a. It is to be noted that the specific illustration of Region A andRegion B is not limited to that shown and described herein but may be asdescribed more fully in the Broeker U.S. Pat. No. 3,354,331. Broekerdiscloses that an electrical stress grading on the electrical windingsbeyond the grounded portion (Region A is the grounded portion herein)may be beneficial. Region B herein is meant to refer to the electricalstress grading region. Layer-like segments 65a, 65b, 65c and 65d aresubstantially similar to layer 18 except for their resistivities.

FIG. 6 is a cross sectional view of an electrical winding 70. Aplurality of conductive strands 72 are bundled together in two adjacentcolumns 73 and 75 respectively. A first strand 76 of column 73 istransposed with respect to a second strand 77 of column 75. An inerttransposition filler material 78 is disposed proximate strand 76 andstrand 77 to round off that end portion of winding 70. Strand 76 istransposed with respect to strand 77 due to the stacking of the strandslongitudinally and the cooling passages in the grouped strands as iscommonly recognized for Roebel bars in dynamoelectric machines.

An internal grading layer includes a semi-conducting pyrolized glassfiber layer 79, having a resistivity in the range of 200 to 100,000 ohmsper square, being disposed between transposition filler material 78 anda heavy insulation 80 which completely surrounds the rounded off, bundleof strands. The semi-conducting layer 79 is electrically coupled tostrand 76 and strand 77 and in intimate contact with insulation 80.

As illustrated in FIG. 6, the bottom most strands of column 73 andcolumn 75 are also transposed and a filler material rounds off that end.A semi-conducting pyrolyzed glass fiber layer caps that end ofelectrical winding 70 in a similar fashion to the aforementionedinternal grading layer. Semi-conducting layer 79 provides an equalelectrical potential about the end regions of electrical winding 70.However, it should be noted that semiconducting layer 79 need only be atone end of electrical winding 70 where the filler material is utilized.

FIG. 7 illustrates a cross sectional view of a cable utilizing asemi-conducting pyrolyzed glass fiber layer to equalize the electriccharge on the exterior of the insulator of the cable and asemi-conducting layer utilized as an internal grading layer surroundingthe conductors within the cable. Cable 100 includes a plurality ofconductive strands 102 surrounded by an internal grading layer 104. Theinternal grading layer is a semi-conducting pyrolyzed glass fiber layeras disclosed herein. Internal grading layer 104 equalizes the electriccharge about conductive strands 102.

An insulation 106 surrounds internal grading layer 104. On the externalsurface of insulation 106, a semi-conducting pyrolyzed glass fiber layer110 equalizes the electrical potential thereon. Semi-conducting layer110 is electrically connected by coupling means 112 to ground by wire114. In a fashion similar to that described above, semi-conducting layer110 bleeds off any static electric charge or electric charge developedon the exterior surface of insulation 106 due to an electrical potentialdifference between conductive strands 102 and the ambient environment.It is to be understood that cable 100 could utilize internal gradinglayer 104 without utilizing semi-conducting layer 110. Also, cable 100could utilize semi-conducting layer 110 without including internalgrading layer 104.

FIG. 8 is a cross sectional view of an electrical housing surroundingsome digital electronic equipment. Electronic equipment generallydesignated as items 201 is housed within structure 210. To protectelectronic components 201, the exterior surface of housing 210 has alayer 212 of semi-conducting pyrolyzed glass fiber. The semi-conductinglayer 212 is substantially similar to the semi-conducting layersdescribed hereinabove. Semi-conducting layer 212 is in electricalcontact with ground 214 by coupling through wire 216 to the retainingmeans 218 in mechanical contact with semi-conducting layer 212. Those ofordinary skill in the art will recognize that if electrical components201 are sensitive to electronic charges accumulating on housing 210,semi-conducting layer 212 will bleed off those electrical charges toground 214 at described in detail hereinabove. Since semi-conductinglayer 212 is composed substantially of a fiber glass material, layer 212can intimately contact housing 210 in the region 220. Prior artgrounding tapes may experience voids or gaps in region 220. It should berecognized that although semi-conducting layer 212 is shown as adistinct element from housing 210 in FIG. 8, a person or ordinary skillin the art would recognize that the entire housing 210 could be composedof the semi-conducting pyrolyzed fiber glass material.

The utilization of the semi-conducting glass fiber layer as describedherein is only illustrative of a broad use of such material. When thesemi-conducting layer is in electrical contact with an electricalground, the layer prohibits the development of a corona discharge, andsubstantially bleeds off any electric charge developed on the exteriorsurface of a finite segment of an insulated conductor. Since thesemi-conducting layer is a glass fiber which can be chopped, mixed withresin and molded, or blown on any complex shaped substrate, the layercan be placed in intimate contact with substantially all of the exteriorsurface of the insulator or housing and substantially all voidstherebetween are eliminated when appropriate bonding agents areutilized. Hence, if the layer is in electrical contact with a bodyhaving a known electrical potential, the exterior surface of the coveredsubstrate has a substantially uniform potential equal to that of thebody. Although the examples herein only illustrate electrically groundedinsulative bodies in combination with the semi-conducting layer, one ofordinary skill in the art will appreciate that any body having a knownelectrical potential may be coupled to the semi-conducting layer toeliminate the effects of ambient electrical fields or charges developedwithin or without the electrical conductor or encompassed components.The description of the electrical windings in a dynamoelectric machineis not meant to be limiting since these electrical windings have similarcounterparts in many types of large motors and other electrical devices.

It is to be recognized that the semi-conducting pyrolyzed glass fiberlayers may have differing levels of resistivity as described withrespect to the end turn region of the dynamoelectric machine discussedherein. Those differing levels of resistivity can be utilized in anelectrical grading system to relieve electrical stress created by theelectrical windings being at a high potential relative the regionsimmediately adjacent the exterior of the insulation. Also, thesemi-conducting pyrolyzed glass fiber layer can be placed in intimatecontact with a number of materials by bonding the layer and materialsurface together by a compatible resin, bonding agent, or otherappropriate means.

The above description details several embodiments of the invention,however, it is to be understood that various other modifications may bemade therein and the claims are intended to cover all such modificationsthat fall within the true spirit and scope of the invention.

We claim:
 1. An internal grading layer for an electrically conductivewinding which includes a plurality of conductive strands bundledtogether in at least two adjacent columns and a first strand of saidplurality of conductive strands being transposed with respect to asecond strand of said plurality of conductive strands in an adjacentcolumn, an inert transposition filler material disposed proximate saidconductive first and second strands to round off that portion of thebundled together conductive strands, said bundled together conductivestrands and said filler material being surrounded by an insulativematerial, the internal grading layer comprising:a semi-conductingpyrolyzed glass fiber layer having a resistivity in a range of 200 to10,000,000 ohms per square disposed between said filler material andsaid insulative material in intimate contact with said insulativematerial and electrically coupled to said conductive first and secondstrands.
 2. A device in an electromagnetic machine comprising:anelectrically grounded core defining axially extending, circumferentiallyspaced, radially directed slots; a plurality of insulated windingsdisposed in said slots, each winding including:a plurality of conductivestrands bundled together in at least two adjacent columns; a firstconductive strand of said plurality of conductive strands beingtransposed with respect to a second conductive strand of said pluralityof conductive strands in an adjacent column; an inert transpositionfiller material disposed proximate said first and second conductivestrands to round off that portion of the bundled together conductivestrands; a semi-conducting pyrolyzed glass fiber layer, having aresistivity in the range of 200 to 10,000,000 ohms per square coveringsaid filler material, being in intimate contact with an outer surface ofsaid filler material and with an insulative material and beingelectrically coupled to at least said first and second conductivestrands; said insulative material substantially surrounding saidwindings; and means for retaining said insulated windings in said slots.